Building method and means



Feb. 6, 1923. 1,444,588. H. L. COPELAND.

BUILDING METHOD AND MEANS. FILED AUG.26,1921.

3 SHEL'TSSHEET I.

A r'roRzv fs.

6, 1923., H. L. COPELAND BUILDING METHOD AND MEANS,

FILED AUG.26,1921. 3 SHEETS-SHEET 3.

- VENTOR. flm? Y [2 54A N0 BY 5 I ATTORNEYS.

Patented Feb. 1923.

UNETEE STATES HARRY L. COPELAND, OF WALLA WALLA, WASHINGTON.

BUILDING METHOD AND MEANS.

Application filed August 26, 1921.

This invention relates to a method of and means for building construction whereby a wall or other structure comprising a formative backing anda unitable face of brick, tile, or the like, may be formed into a monolith in one operation.

()ne object of the invention is to provide a methodof construction that will not require skilled labor and that will produce an exceedingly high grade work in a relatively short period of time.

A further object of the invention is to provide a means of construction whereby the facing is placed in position before the Wall is formed and after placing forming the structure.

A further object of the invention is to provide a means of construction whereby a structure having an ornamental facing may be constructed in the manner of concrete construction, i. e., the concrete carrying the load of the structureand therefore by taking the weight off the facing permit the use of a facing of much less depth and still bond the facing to the structure permanently.

A' further object of the invention is to provide a means of construction whereby a relatively thin formative material may be utilized without waste and thus provide a stronger structure.

A. further object of the invention is to provide a means whereby a formative structure having a finished or ornamental face may be constructed by spouting.

A further object of the invention -is to provide a means of construction whereby the wall is covered by a form and yet the individual units are exposed for observation.

A further object of the invention is to provide a means of construction whereby figures and color schemes in the facing of the structure may be worked out by unskilled labor.

A further object of the invention is to provide a means of construction whereby the facing of a formative structure composed of a formative backing and a unitable facing may be laid in Various forms of bond.

Serial N0. 495,665.

llith these and further objects in view, which will be presented as the description proceeds reference is now had to a brief description of words which will be used in the specifications and claims.

The word plastic will be used to describe the state or condition of the backing to embrace the various consistencies of material which may be used: from a liquid state to that of a semi-hard state such as that of putty, plaster, or the like.

In laying brick or other facing by this process the condition of the backing will depend on either the amount of moisture in the units composing the facing or the required distance of flow of the mortar.

(Mortar being used in this sense to designate that part of the backing which fills the interstices between the units of the facing.)

Where the units are relatively dry suflicient moisture must be added to the backing to induce a flow of the mortar between the units to thus form the necessary bond and where the units have sufficient moisture the state of the backing must be such that the flow of mortar will partly or completely fill the interstices as required, for instance if pointing it required obviously the mortar must. remain back from the surface of the facing.

The word formative as used to describe the structure and backing will designate a material which will set to form, i. e., which may be plastic, liquid, or semiliquid, as mortar, plaster, or the like.

The word unitable as applied to the facing will designate a facing composed of units which when bonded to the formative structure unites to form a complete facing.

Reference is now had to the accompanying drawings in which Fig. 1 is a perspective view of the forms showing their application to various ramifications of building construction;

Fig. 2 is a side elevation of the facing form, or panel, showing reverse and obverse sides;

Fig. 3 is a plan and sectional view of the facing panel on the line 33 of Fig. 2, and shows an end gate in place;

Fig. i is an end view in section of the panels showing one method of tying the panels together;

Fig. 5 is a plan view of the expansible yoke;

Fig. 6 is a side elevation of the yoke,

Fig. 7 is a plan view of the yoke in its expanded position;

Fig. 7" 1s a sectional view of the yoke on the line 7 a of Fig. 7;

Fig. 8 is a front elevation of the panel lock in the locked position;

Fig. 9 is a front elevation of the panel lock in the unlocked position;

Fig. 10 is a plan view of the panel lock;

Fig. 11 shows bolt hole for the lock in the frame of a panel;

Fig. 12 is a front elevation of the tie rod catch;

Fig. 13 is a plan view of the tie rod;

Fig. 14 is a side elevation thereof;

Fig. 15 is a sectional end elevation of the panels showing end gate in place;

Fig. 16 is an enlarged sectional end elevation of part of a, facing panel showing method of supporting facing units;

Fig. 17 shows a section of a back panel with a wood plug in position to become 1mbedded in the structure;

Fig. 18 is a side elevation of the lowering and supporting member;

Fig. 19 is a plan view from below of the lowering and supporting member;

Fig. 20 is a front elevation of an attachable supporting shelf and gauge;

Fig. 21 is a plan view thereof;

Fig. 22 is a plan view of a section of wall showing old method of bonding;

Fig. 23 is a plan view of a section of wall showing improved method of bonding; and

Fig. 24 is an end elevation of the facing showing method of constructing a sunken course.

In the drawings like numerals refer to like parts throughout the several views and the numeral 1 refers to a structure in the nature of a wall having a backing 2 composed of a formative material, and a unitable facing 3 consisting-of units 4, the units being first placed in their final position after which the formative material is deposited in a manner to firmly bond the unitable fac- I ing and the backing into a monolithic mass.

The units may be common brick, facebrick, tile, mosaic, marble, or other suitable facing, and the backing may be of concrete or other'formative material which will form a bond with the facing.

Obviously where a plastic backing is poured or placed against a facing having interstices between its units the formative material will fill the interstices and form a most substantial bond, however certain courses may be further bonded by chipping off the corners 5 of the units as shown in Fig. 23, which will'permit a greater mass of the formative material to enter and form a bond if this method is deemed necessary. This method of bonding the backing into the facing eliminates the necessity of a bonding course as shownin Fig. 22 where the facing is bonded into the backing by the units 6.

This method of bonding the backing into the facing will obviously permit the use of a unit having about half the usual depth which will reduce the cost of the facing considerable.

In this method of construction the order of things is reversed and where formerly a wall was constructed and a facing afterwards built against it using various means to prevent separation of the two parts, now with this invention the facing is placed in its final position and the backing deposited against the facing resulting in a structure that is monolithic. 1

One means by which this method may be carried out will now be described.

A form is provided which consists of a facing panel 7, a back panel 8. and yokes 9 The number of panels will be determined by the length of the work.

The facing panel 7 consists preferably of a plate 10 of metal which is perforated by cutting out two sides of a triangular piece which being bent at right angles to the plate 10 to a horizontal position, forms a shelf 11 wherewith to support a unit of the unitable facing.

The shelves are so arranged that a predetermined amount of space is left between the units to be filled by the backing as above described.

A second triangular cut is made in the plate 10 and this piece is also bent at right angles to a vertical position to form a gauge or stop 12 wherewith to maintain a unit in a true position longitudinally.

These triangular pieces now form an open pocket, which when filled with the units, supports and maintains in proper alignment and position all the units carried by the panel.

The orifices, or'perforations, left in the plate 10 now become sight openings 11 through which the position of a unit mav be observed and corrected. if necessary, manipulating the formative backing with a tamper or other means. Obviously facing units of various colors may be used where special color designs and ornan'ientations are wanted, and by means of the sight openings the proper patterningof the units will be visible.

The shelves are so spaced longitudinallv that a whole or half unit may be supported where occasion requires, and while the vertical spacing will ordinarily be thesame. yet should a thinner course be desired, as shown at 13 in Fig; 16, a special form mav be utilized having the proper spacing. I

Referring again to the spacing, the shelves 11, or the shelves and stops 12 together. as shown in Figs. 2 0 and 21, may be separate from the panel to which they may be attached by means of small bolts or rivets and spaced to form any design such as basket weave, herring bone, or the like: and

this odd spacing may be carried further to provide for arches, where a special arch form is not available.

By referring to Fig. 24 it will be noted that one of theunits 14 is out of line horizontally as for a sunken course; thus by the addition of a block 15 placed between the unit and the panel a sunken course will be obtained. Care will be used in placing the block not to cover the sight openings.

And further, by placing a sheet of thin metal, (not shown) in the place of a unit, so as to cover the sight openings, the backing will flow to the face ,of the wall and a new form of ornamentation consisting of alternate (if you like) units of different materials one of which corresponds to the backing. In this case observation for alignment is unnecessary and by closing the sight openings leakage of the backing is prevented. v

The back panel 8 is positioned directly opposite to the facing panel and consists ordinarily of a blank sheet 16, however where both sides of the structure are faced facing panels may be used on both sides of the structure.

Both panels are suitably strengthened by angle iron frames 17, or other suitable means.

Various locking means to hold the panels in place are employed andthese will now be explained: I

The yokes 9, 9 are provided to hold the facing and back panel a distance apart corresponding to the required thickness of the structure and to maintain the panels plumb. They are also made expansible to conform to various sizes of walls, expansion being obtained by providing offsets 18 in the head 19, and a catch 20 which holds the two portions ofthe head in engagement with each other in their proper offsets.

Legs 21' extend downward from the head and pass through the slotted holes 22 of the frame of the panelsand straddle the structure. The legs carry on their lower extremities a plumb gauge 23 which consists of a projecting piece extended to engage the finished structure and to come flush or plumb with the inner face of the panel when the yoke is in the operable position, as shown in Fig. 1.

The yoke may be removed from the panels by turning the plumb gauge to pass through the slotted hole 22 and removing the yoke therefrom.

Preferably on the bottom of the frame are lowering and supporting members 24 which consist of a slotted tongue 25, tapered at the point 26, and rotatably and withdraw-' ably mounted to the frame by the rivet 27 which passes loosely through the slot 28. These members are extended inward and rest on the finished work to support the panel while the formative backing is placed; then to remove the panel the tongue is withdrawn and rotated to the position shown by the dotted lines in Fig. 19 when the panel will have a tendency to drop and thus become free for removal.

To give greater rigidity to the panels against bulging due to tamping or other causes the panels are joined together by a tie rod 29 having a head 30 at one end to rest against the panel and slotted 31 at the other end to be engaged by the latch 32 which is slidably attached to the panel and which is slotted at 33 to engage the slots 31 of the tie rod. By this means the tie rod is maintained in the panels through which (and the wall) it has been passed, and it is so locked that it cannot be withdrawn.

For locking the ends of the panels together the bolt 34 is provided with a stem 35 slidably mounted in a bearing piece 36, and on the end of the stem are tits 37. shown plainly in Fig. 10, which will now be explained:

The frames have slotted holes 38 punched therein to receive the stem, which when passed through the holes and turned by the handle 39 brings the tits on both sides of the frame and against the face 40 thereof in a manner to lock the frames of adjacent panels together and at the same time preserve the horizontal and lateral alignment.

End gates 41 are provided which are preferably of sheet metal and which have sup porting clips 42 attached thereto to rest on the to of the panels. The clips may be provi ed with points 43 to engage holes 44 in the frame.

Vertical alignment of the end gate is obtained by utilizing the stops 12 as shown in Fig. 15 and in the reverse portion of the plan view shown in Fig. 3.

To provide a, means for nailing furring strips, etc. to; the wall a hole may be made in the back panel and a wood plug 45 inserted, as shown in Fig. 17. I. fter removing the panel the plug, which extends out to be firmly held by the panel, may be sawed off.

In operation the foundation course will be laid and the panels set by the means above described; after which the facing units are placed in the pocket of the panels and the formative backing is deposited between the units and the back panel and tamped until the interstices between the units are properly filled. The tamping will also act as a means to force back against the panel any unit which may have moved out of position.

The usual practice in brick laying has been to lay a header course for bonding purposes every sixth course; therefore as the shelves are so spaced as to take half a unit a header course as shown at 46 in Fig. 1 may be laid by extending the unit toward the center of the structure, where a header course is reuired, however as above mentioned a perfeet bond is obtained in this method without the necessity of a header course.

Obviously the facing units can be laid from within the structure and hence no outside scaffold is required.

Broken ieces of the units can be deposited in the bac ing with the formative material and thus be utilized instead of wasted.

Short panels may be used to complete a stretch of forms int which case they will be equipped with similar pockets to those of the full size panels.

In placing the formative backing a thinner mixture composed of finer materials may be used and hence spouting may be adopted without danger of the conglomerates separating in the depositing backing.

And further a thinner mixture produces a greater bond and therefore has greater strength, and with the units supported by'the pockets a thinner mixture can be used without danger of the units getting out of line as where they have to depend upon the mortar for support.

The trowel is an instrument made use of to spread the cement which unites the building into one common mass, but by this method of construction the use .of the trowel is eliminated as the mass is formed in one common mold or form by a method which unites the whole as one.

claim:

1. In a structural form, a facing panel, open pockets for maintaining the units of a facing in spaced relation with each other and against said facing panel, a back anel, and means for locking said facing an back panel together across the structure, through the structure. and along the face of the structure.

2. In a structural form, a facing panel, inwardly extending shelves in said facing panel, means for gauging the spacing of the units of the unitable facing of the structure. a back panel. an expansible yoke, positioned to straddle the structure and maintain said facing and said back panel plumb with the finished structure, lowering and supporting members movably attached to said panels,

' and means to lock adjacent panels together.

3. In a structural form, a facing panel, inwardly extending shelves in said panel, gauging means attached to said panel, a back panel, an expansible yoke removably attached to said facing and back panel, tie rods attached to and joining said facing and back panel, and means to lock adjacent panels together.

4. In a structural form, a facing panel,

Having thus described my invention, I

against horizontal movement, and meansfor locking adjacent panels together.

5. In a structural form, a facing panel, supporting shelves extending inwardly from said panel and spaced to support a unit or part of a unit of the unitable facing of the structure, sight orifices in said panel, a back panel, an expansible yoke, provided with legs and removably attached to said panels, gauge members attached to said legs, lowermg and supporting members movably attached to said panels at the base thereof, tie

rods joinin said panels, means for locking said toe rods to the facing panel, and bolts attached to said panels to rigidly engage an adjacent panel.

6. In a structural form, facing panels, shelves attached to said panels, orifices in said panels, spacing gauges in said panels, back panels, expansible yokes removably mounted in said panels, legs attached to said yokes, gauge members attached to said legs and positioned to automatically register with the face of the finished structure when the yokes are brought to an operable position, and bolts operably attached to said panels to rigidly engage adjacent panels.

7.111 a structural form, in combination, a facing panel, provided with a supporting means and a spacing means cut from said panel, said cutting providing sight orifices therein, a back panel, an expansible yoke provided with a plumb gauge attachedto said panels, tie rods joining said facing and back panel, said rods provided with slots ,on one end thereof, a latching means slidably mounted on the face of one of said panels, to register with the slots of said tie rods. lowering and supporting members operably attached to said panels. and bolts attached to said panels -to rigidly engage adjacent 

